INSTRUCTIONS FOR KIT #4404570
4” DIESEL KIT CAT-BACK KIT
FITS:
2003-2004 FULL-SIZE
FORD 3/4 & 1 TON F SERIES W/6.0L POWERSTROKE TURBO DIESEL, 2WD
& 4WD,
ALL WHEEL BASES (137”-172.4”), THIS IS A CAT-BACK EXHAUST KIT, FOR
VEHICLES
WITH CATALYTIC CONVERTER.
NOTE: DO NOT TIGHTEN
ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!
READ THESE INSTRUCTIONS FULLY AND THOROUGHLY BEFORE YOU BEGIN. BEFORE DOING ANY CUTTING, VERIFY THAT THE
LENGTH TO CUT OFF IS CORRECT.
NOTE: DUE
TO THE EXTREME DIFFICULTY OF REMOVING, MODIFYING,
AND INSTALLING THE DOWN PIPE, IT IS NOT INCLUDED IN THIS EXHAUST SYSTEM. THE DOWN PIPE KIT MAY BE ORDERED THROUGH J.C.
WHITNEY SPECIAL ORDERS DEPARTMENT, PART NUMBER IS #4004571. WE RECOMMEND THIS DOWN PIPE ONLY FOR VERY
ADVANCED AND PATIENT INSTALLERS. YOU
MAY NEED TO CUT YOUR O.E. DOWN PIPE IN NUMEROUS PIECES TO REMOVE IT. THE CONVERTER AND DOWN PIPE ARE NOT INCLUDED
IN THIS KIT.
1) REMOVE THE EXHAUST SYSTEM AFTER THE CONVERTER. REMOVE THE WIRE HANGERS FROM THE O.E. RUBBER
HANGER MOUNTS (A LUBRICANT MAY BE NECESSARY), BUT LEAVE THESE RUBBER
HANGER
MOUNTS ON THE TRUCK.
2) THE
EXTENSION
PIPE (47” STRAIGHT PIPE SHRUNK TO 3-1/2”) WILL FIT THE CREW CAB LONG
BOX MODELS
(172.4” WHEEL BASE). ON THE SHORTER
WHEEL BASE MODELS, YOU WILL NEED THE EXTENSION PIPE TO LENGTH, FROM THE
4” O.D.
END, THE END THAT IS NOT SHRUNK:
CREW CAB LONG BOX (172.4”)
EXTENSION PIPE LENGTH = 47”
NO
CUTTING
CREW CAB SHORT BOX (156.2”)
EXTENSION PIPE LENGTH = 30.8”
CUT
OFF 16.2”
SUPER CAB LONG BOX (158”)
EXTENSION PIPE LENGTH = 32.6”
CUT OFF 14.4”
SUPER CAB SHORT BOX (141.8”) EXTENSION
PIPE LENGTH = 16.4”
CUT OFF 30.6”
REGULAR CAB LONG BOX (137”) EXTENSION
PIPE LENGTH = 11.6”
CUT
OFF 35.4”
3) USE A 3-1/2" CLAMP TO ATTACH THE EXTENSION
PIPE TO THE CONVERTER.
4) INSTALL THE FRONT 4” HANGER CLAMP TO THE
EXTENSION PIPE, AND ATTACH THE WIRE PORTION TO THE O.E. HANGER ALONG
SIDE THE
PIPE.
5) INSTALL THE MUFFLER TO THE EXTENSION PIPE
USING THE MIDDLE 4” HANGER CLAMP (TWO WIRE HANGERS ON THIS HANGER
CLAMP). NOTE:
THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS
OF THE
MUFFLER.
6) INSTALL THE TAIL PIPE TO THE MUFFLER USING
THE MIDDLE 4” HANGER CLAMP (TWO WIRE HANGERS ON IT) AT THE CONNECTING
POINT OF
THE TAIL PIPE AND MUFFLER. INSTALL THE
WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNTS
ABOVE.
7) INSTALL THE REAR TAIL PIPE 4” HANGER CLAMP TO
THE TAIL PIPE BEFORE THE LAST BEND AND BELOW THE O.E. RUBBER HANGER
MOUNT. INSTALL THE WIRE PORTION OF THE
HANGER TO THE
O.E. MOUNT ABOVE.
8) FOR THOSE WITH DUALLY MODELS, YOU WILL NEED
TO INSTALL THE TAIL PIPE EXTENSION TO THE TAIL PIPE USING BY EITHER
WELDING
(RECOMMENDED FOR APPEARANCE REASONS) OR USING A 4” CLAMP (INCLUDED). YOU MAY NEED TO TRIM TO LENGTH AND STYLE OF
CUT.
9) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR
CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.
HARDWARE
KIT FOR KIT
#4404570:
1) TAIL PIPE EXTENSION # 4405507
1) FRONT 4” HANGER CLAMP # 2997SS
1) FRONT EXTENSION PIPE # 4404573
1) MIDDLE 4” HANGER CLAMP # 2996SS
1) TAIL PIPE # 4405505
2) 4” STAINLESS STEEL CLAMPS
#MC7400SS
1) MUFFLER #5024-114SS
1) REAR 4” HANGER CLAMP # 2995SS
`
1)
3-1/2” STAINLESS STEEL CLAMP #MC7312SS
INSTRUCTIONS FOR KIT #4404570
4” DIESEL KIT CAT-BACK KIT
DANGER
WARNING:
SHOULD THE
PURCHASER DECIDE TO INSTALL THIS, OR ANY OTHER EXHAUST PRODUCT AT HOME,
BE
WARNED THAT PLEASURE CAR OR LIGHT DUTY TRUCK/VAN "BUMPER JACKS" ARE
INTENDED FOR EMERGENCY USE ONLY. THE USE
OF FRAME CONTACT JACK STANDS IN CONJUNCTION WITH A FLOOR JACK AS MAIN
SUPPORT
IS HIGHLY RECOMMENDED TO MINIMIZE ACCIDENTAL DROPPING OF A VEHICLE
WHILE THE
INSTALLATION PROCEEDS.
Limitation
of
liability--Disclaimers: The regulation of emissions production, noise
levels and safety standards is undertaken by the federal government,
each of
the fifty state legislatures, and by many local municipalities, towns
and
counties.
The manufacturer makes no warranties of
merchantability, of fitness for a particular purpose, or that its
products are
approved for general use, or that its products comply with laws,
regulations or
ordinances in the states where they may be sold to the ultimate
purchaser, the
consumer.
The entire risk as to the conformity of this product
in any such state and as to repair, should the product prove to be
defective or
non-conforming, is on the retail purchaser, the buyer, the ultimate
consumer of
such product and it is not upon the seller, distributor, or
manufacturer.
In this connection, retail purchaser, the buyer, the
ultimate consumer assumes the burden of the entire cost of any and all
necessary service, alterations, and or repair.
The foregoing statement limits the liability of the
manufacturer.
FOR
DETAILED DIGITAL
PICTURES OF THIS SYSTEM INSTALLED EMAIL US AT:
HEARTTHROB@WILLMAR.COM
NOTE: THIS KIT
IS MADE OF 409 STAINLESS STEEL. IT MAY
BE BROWNISH IN COLOR, AND A MAGNET WILL STICK TO IT.